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Technology in the Potash IndustryTechnology in the Potash Industry

Presented to:Presented to:

U of S Mechanical EngineeringU of S Mechanical Engineering

October 10, 2002October 10, 2002


Technology in the Potash IndustryTechnology in the Potash IndustryPresentation OutlinePresentation Outline

?? PotashPotashCorpCorp

?? Mining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics

?? ProcessProcess

?? Products Products

?? EnvironmentEnvironment


PotashPotashCorpCorp ProfileProfileTechnology and Corporate GoalsTechnology and Corporate Goals

Customers for PCS Potash

5.7 billion people1.42 Gha arable land

• Technology leader

• Best products

• Low cost producer

• Safe operations

• 2500 m2/person


PotashPotashCorpCorpBusiness ProfileBusiness Profile

?? Produce, market and transport N, P and K products:Produce, market and transport N, P and K products:

•• Plants in USA (N+P), Canada (K), Trinidad (N) Plants in USA (N+P), Canada (K), Trinidad (N)

•• PCS operates 5 potash mines in SK and 1 in NB PCS operates 5 potash mines in SK and 1 in NB

•• 2001 Sales: 16.6 million 2001 Sales: 16.6 million tonnestonnes of N, P and K productsof N, P and K products

?? Financial 2001: Financial 2001:

•• Assets: $4.6 billion US Assets: $4.6 billion US

•• Net Sales Revenues: $2.07 billion USNet Sales Revenues: $2.07 billion US

•• Employees: 4997Employees: 4997


PCS Nitrogen and PCS PhosphatePCS Nitrogen and PCS PhosphateAmmonia, Urea, Phosphoric acid, Solutions, FeedsAmmonia, Urea, Phosphoric acid, Solutions, Feeds

PCS Phosphate at Aurora, North Carolina


PCS PotashPCS PotashMines in Saskatchewan and New BrunswickMines in Saskatchewan and New Brunswick

Rocanville, SK

Sussex, NB


Impacts on Revenues, Costs and RisksImpacts on Revenues, Costs and RisksTechnology in BusinessTechnology in Business

Profit = Revenue Profit = Revenue -- Cost Cost -- RiskRisk•• Revenue:Revenue:

–– Sales of products: MarketplaceSales of products: Marketplace

–– Investment incomeInvestment income

•• Cost:Cost:–– OperationsOperations

–– MaintenanceMaintenance

–– TransportationTransportation

•• Risk:Risk:–– Probability x ConsequenceProbability x Consequence





?? ProcessProcess




Potash Deposits in SaskatchewanPotash Deposits in SaskatchewanDevonian Period, Devonian Period, --350 Ma350 Ma

• Seas covered continent

• Mountain uplift, then cutoff

• Solar evaporation concentrated brine

• Sea water concentrated

• Chloride salts crystallized in sequence

• Now buried by 1000 m of sediments


Profits= RevenuesProfits= Revenues--CostsCosts--RisksRisksMining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics

• Mining at -1000 m

• Multi-pass room and pillar

• Stress relief chevron method

• Continuous, mechanized system

• High Productivity

• Automated, 3-D control of miners

• Safe operations


Continuous Mining SystemsContinuous Mining SystemsPlan View of Mining PanelsPlan View of Mining Panels

?? Room and Pillar MiningRoom and Pillar Mining•• Needs stable, flat ore bodyNeeds stable, flat ore body

•• MultiMulti--pass cutting of roomspass cutting of rooms

•• Can use automated minersCan use automated miners

•• Ore extraction in panels: 42%Ore extraction in panels: 42%

?? Stress Relief MiningStress Relief Mining•• Used in clayUsed in clay--banded orebanded ore

•• Complex cutting patternComplex cutting pattern

•• Some automationSome automation

•• Ore extraction in panel: 65%, Ore extraction in panel: 65%, (42% overall)(42% overall)


Continuous Mining SystemsContinuous Mining SystemsMechanization andMechanization and AutomationAutomation

Lanigan Division 4-Pass Systemwith moveable extensible panel conveyor

Fixed mainline conveyor moves ore to the mine shaft

14.6 m

4.9 m


Continuous Mining SystemsContinuous Mining SystemsTriTri--axial Control of a Mining Machine in the Ore Horizonaxial Control of a Mining Machine in the Ore Horizon

X: Laser beam guidance system for 1st pass miningAdvance rate sensor

Y: Ultrasonic sensors for 2nd and 3rd pass mining

Z: Vertical array of K-40 gamma radiation sensors for optimum ore gradeClay seam sensor

Z

X

Y


Mining Machine PerformanceMining Machine PerformanceBit and Pattern Design for Best Cutting EfficiencyBit and Pattern Design for Best Cutting Efficiency

Bit Design:

Reduce bit wear and frequency of replacementIncrease machine availabilityReduce fines and dust from primary rock fragmentation

Tooling Pattern:

Improve energy efficiencyIncrease average particle size of broken ore


Mining Machine PerformanceMining Machine PerformanceDesign for Elimination of the Trim ChainDesign for Elimination of the Trim Chain

Cutting Profile Goals:

Rectangular opening

No cusps

Reduce dust and fines

Principle:

Cam-following cutting arm extensions

SK Design:

Prairie MachinePrototype at IMC Colonsay


Ore Body Geology Ore Body Geology Technologies to Detect Geological Disturbances Technologies to Detect Geological Disturbances

Stratigraphy

Aquifers above and below the highly soluble ore body

are potential sources of inflow water, particularly near

collapse structures

Dep

th, m

etres

Ore


GeoscienceGeoscience Helps to Prevent Mine FloodingHelps to Prevent Mine Flooding33--D Seismic Surveys to Detect and Avoid Major Anomalies D Seismic Surveys to Detect and Avoid Major Anomalies

Seismic Data Collection:

1-D geophone string yields information on structures in 2-D plane

2-D Geophone surface array yields 3-Dinformation

Rocanville Division Collapse Structure:

Image shows elevations of the top of the Dawson Bay formation that lies above the evaporite salts

First application of 3-D seismic method by PCS to confirm a collapse anomaly

High

Low

1600 m


Managing Potash Mine FloodsManaging Potash Mine FloodsSuccessful Plug Installed at the Successful Plug Installed at the RocanvilleRocanville Division Division

Location of mined rooms in panel


Rock MechanicsRock MechanicsMaterials Properties Measurement in the LaboratoryMaterials Properties Measurement in the Laboratory

Instrumented Tri-axial Test Cells 15 cm diameter core of potash ore shows strain after testing


Rock MechanicsRock MechanicsMine Monitoring and Modeling Mine Monitoring and Modeling

Rock mechanics monitoring station.Deformation of rock is measured.

Data logged underground are transmitted to the surface for analysis

2-D and 3-D numerical modeling of the displacement and stress distribution around mine openings in viscoelastic rock helps to ensure stability and safety

Effect of stress relief slot cut in roof

High

Low





?? ProcessProcess




Processing Potash OreProcessing Potash OreMineral SeparationMineral Separation and Particle Sizing Unit Operationsand Particle Sizing Unit OperationsProfits= Profits= RevenuesRevenues--CostsCosts--RisksRisks

?? Crushing and SizingCrushing and Sizing

?? DeslimingDesliming

?? FlotationFlotation

?? CrystallizationCrystallization

?? DryingDrying

?? Compaction and ScreeningCompaction and Screening

?? Product HandlingProduct Handling

?? Tailings ManagementTailings Management

Mill Feed Rates are up to 1400 tonnes/hour


Processing Potash OreProcessing Potash OreOre MineralogyOre Mineralogy

?? Composition:Composition:•• NaCl: NaCl: 55%55%

•• KCl:KCl: 3535--40%40%

•• KMgClKMgCl33.6H.6H22OO:: 11--5%5%

•• InsolublesInsolubles: : 11--8%8%

?? Size Range of Natural Crystals Size Range of Natural Crystals in Ore:in Ore:•• 11--10 mm10 mm

3 mm


Processing Potash OreProcessing Potash OreParticle Size Distributions of Potash ProductsParticle Size Distributions of Potash Products

Particle Size Distributions of Selected Grades of Potash Examples of Standard, Coarse and Granular Products

0

10

20

30

40

50

60

70

80

90

100

0.0 1.0 2.0 3.0 4.0

Particle Size, mm

Fine Standard

Pink Standard

Red Standard

White Standard

Pink Coarse

Red Coarse

White Coarse

Pink Granular

Red Granular

White Granular


Processing Potash OreProcessing Potash OreOre Preparation for Flotation by DeOre Preparation for Flotation by De--slimingsliming

PCS Lanigan Flotation Summary

Fines conditioning

Desliming

Primary scrubbers

Brine

Raw Ore RecrushingDesliming screens

Wet Sizing

Primary Cyclones

Secondary scrubbers

Secondary Cyclones

Tertiary Cyclones

Coarse conditioning

Hydros

To scavenger flotation


Processing Potash OreProcessing Potash OreOre Preparation for Flotation by DeOre Preparation for Flotation by De--slimingsliming

De-sliming cyclones separate -150 micron particles from

coarse slurries of potash ore


Processing Potash OreProcessing Potash OreMineral Separation by FlotationMineral Separation by Flotation

Parallel Banks of Flotation Cellunits operating in series

KCl-rich slurry is removed as Concentrate


Processing Potash OreProcessing Potash OrePrinciple of Separation by FlotationPrinciple of Separation by Flotation

?? Feed slurry:Feed slurry:

•• NaCl + KCl + NaCl + KCl + InsolsInsols

•• CoCo--saturated brinesaturated brine

•• ReagentsReagents

–– DepressantDepressant

–– CollectorCollector

?? Concentrate:Concentrate:

•• Mainly KCl slurryMainly KCl slurry

?? Tailings:Tailings:

•• Mainly NaCl slurryMainly NaCl slurry


Processing Potash OreProcessing Potash OreFlotation Process Flotation Process FlowsheetFlowsheet

PCS Lanigan Flotation Summary

Frother (MIBC)Brine

DepressantFlocculant

Starch

Starch

Extender

Amine

Amine

Brine

Starch

Amine

Extender

Frother

Tails

Tails

XLR CycloneU/F

Dryers

Rougher & Regrind Flotation


Processing Potash OreProcessing Potash OreMechanical Cell Banks Separate Particles by Size

Rougher Flotation Particle Size Distribution

0

5

0.0 1.0 2.0 3.0 4.0

Particle Size (mm)

KC

l Mas

s Fl

ow, %

T

C1

C2

C3

C4

C5

C6


Processing Potash OreProcessing Potash OreRate of Flotation Depends on Particle Size

KCl Grade vs Recovery Flotation Data

0

10

20

30

40

50

60

70

80

90

100

40 50 60 70 80 90 100

Grade (%KCl)

KC

l Rec

ove

ry (

%)

+6

+8

+10

+14

+20

+28

+35

+48

+65

-65

Fines: high recovery, low grade

• Coarse: low recovery, high grade

Mesh Size


Processing Potash OreProcessing Potash OrePrinciple of KCl Recovery from Brine by CrystallizationPrinciple of KCl Recovery from Brine by Crystallization

3 Stage Crystallization at the Cory Division

1012

14

16

182022

2426

2830

60 70 80 90 100

Temperature, oC

NaC

l and

KC

l, W

t % Supersaturated KCl

NaCl


Processing Potash OreProcessing Potash OreCrystallizer Vessel and ComponentsCrystallizer Vessel and Components

3.65 m

0.46 m

1.37 m

2.89 m

5.85 m

5.49 m

2.99 m

0.76 m

Hot Brine Feed KCl Slurry


Processing Potash OreProcessing Potash OreMass Flows of Solids and BrineMass Flows of Solids and Brine

Water Evaporation, 4.4 kg/s

Overflow Brine404 kg/s

4550 kg/s Density=Quiet (10 x Feed) Quiet 1.24 kg/LZone Zone

84 oC

Feed Brine Product 30% Solids Outat 96 oC 46.9 kg/s

455 kg/s Density=Density= 1.47 kg/L1.24 kg/L

Draft Tube Top and Bottom Views


Processing Potash OreProcessing Potash OreTypical Crystal Size Distribution of KClTypical Crystal Size Distribution of KCl

Particle Size Distribution

0.1 1 10 100 1000 3000

Particle Size (µm)

0

2

4

6

8

10

12

14

Vol

ume

(%)

PPxlr M-108-6b, 21 Dec 1999 11:38:51

Maximize Growth

Rate = f (S*)

Minimize Nucleation

Rate = f (S*)3


Crystallizer Product CharacteristicsCrystallizer Product CharacteristicsProcessing Potash OreProcessing Potash Ore

?? 600600--1200 micron particles1200 micron particles•• rounded by abrasionrounded by abrasion

•• compositescomposites

?? 300300--425 micron particles425 micron particles•• complex microstructurescomplex microstructures

•• agglomeratesagglomerates

?? 150150--212 micron particles212 micron particles•• primary KCl cubesprimary KCl cubes

•• some agglomerates some agglomerates


Processing Potash OreProcessing Potash OreMineral Separation and Mineral Separation and Particle Sizing Unit OperationsParticle Sizing Unit OperationsProfits= Profits= RevenuesRevenues--CostsCosts--RisksRisks





?? DryingDrying




Mill Feed Rates are up to 1400 tonnes/hour


Processing Potash OreProcessing Potash OreCompaction and ScreeningCompaction and Screening

Compactors compress fine particles into sheets before crushing and screening into marketable products. Important variables are feeder design, roll dimensions, speed, surface contour and materials of construction.


Processing Potash OreProcessing Potash OreCompaction Circuit Compaction Circuit FlowsheetFlowsheet SimulationSimulation

Compactor

Crushers

Screens


Processing Potash OreProcessing Potash OreProduct Storage and TransportationProduct Storage and Transportation


Processing Potash OreProcessing Potash OreProfits= Profits= RevenuesRevenues--CostsCosts--RisksRisks





?? DryingDrying





Technology in the Potash IndustryTechnology in the Potash IndustryOutline of the PresentationOutline of the Presentation



?? ProcessProcess

?? ProductsProducts



Potash Product Quality ManagementPotash Product Quality ManagementMaterials Science FundamentalsMaterials Science Fundamentals

Moisture uptake and release from packed

beds of stored potash can occur rapidly,

depending on RH, temperature, particle

size and type.

Brine films on the surface of the potash

particles are controlled by minerals deposited

from brine during the drying process. KCl, NaCl

and MgCl2 minerals affect moisture dynamics.

SEM image shows cluster of Mg-rich solid.


Potash Product Quality ManagementPotash Product Quality ManagementMaterials Science FundamentalsMaterials Science Fundamentals

Compacted Granular potash

products creep under applied

stress at high RH typical of

tropical and coastal climates

for fertilizer storage


Potash Product Quality ManagementPotash Product Quality ManagementModeling Moisture Transport in Hygroscopic FertilizersModeling Moisture Transport in Hygroscopic Fertilizers

U of S-PCS-NSERC Research Program





?? ProcessProcess

?? ProductsProducts



Environmental ManagementEnvironmental ManagementProfits = RevenuesProfits = Revenues--CostsCosts--RisksRisks

Aerial photo of a potash mine

site showing tailings pile and

brine pond

About 2 tonnes of salt and insolubles waste solids is

separated for each tonne of potash produced


Environmental ManagementEnvironmental ManagementRisk ProfileRisk Profile

Salt piles are expected to grow during the

lifetime of potash mines in Saskatchewan.Decommissioning plans assume that slowdisappearance of salt will occur by dissolution in precipitation.

Risk of contamination of groundwater in

aquifers by brine seepage is low because

of low gradients, low permeability tills, and

effective containment systems.


Environmental ManagementEnvironmental ManagementAlternative Technologies for Tailings DisposalAlternative Technologies for Tailings Disposal

Stabilize

Surface

Cover/Cap

Dissolve SaltsInject Brine

Underground

Backfill Mine


Technology in the Potash IndustryTechnology in the Potash IndustryThe PresentationThe Presentation



?? ProcessProcess




Technology in the Potash IndustryTechnology in the Potash IndustryThe PresentationThe Presentation

Customers for PCS Potash

5.7 billion people1.42 Gha arable land

Profits = RevenuesProfits = Revenues--CostsCosts--RisksRisks

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